Friction stir welding method and apparatus

ABSTRACT

Friction stir welding (FSW) method and apparatus are provided by which power needed for the FSW is reduced and a compact FSW tool can be used. In the FSW method comprising the steps of lapping metal members one on another and inserting a rotating probe of a FSW tool into a contact portion of the metal members making contact with the probe so that the contact portion is softened by frictional heat and stirred by the probe and the metal members are welded together, a portion of the metal members surrounding the probe is heated by a heating means.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a friction stir welding method and apparatus by which a conductive material, such as aluminum (including aluminum alloy) or the like, and other magnetic materials are welded by a friction stir welding (hereinafter the friction stir welding is referred to as “FSW”).

2. Description of Related Art

In every case of a conventional FSW method, a frictional heat is made use of such that a FSW tool comprises a probe and a shoulder portion and while the probe is inserted into a weld portion to be welded by the FSW and the shoulder portion is urged against members, such as metal members, to be welded (hereinafter referred to as “weld object members”), the FSW tool is rotated. For this reason, the FSW tool is needed to have a strong rigidity so as to withstand the urging force. Also, a large power is needed so that the FSW tool is forcibly rotated so as to maintain the friction.

Moreover, with respect to the weld object members also, a reinforcing means is needed in order for the weld object members to be supported against the urging force given by the FSW tool.

Also, in order to obtain a desired frictional heat, a diameter of the probe is sometimes needed to be made larger than a size needed for stirring the weld object members. If weld object members, such as hollow members, have therein a bone member for reinforcement under the weld portion, there is a restriction that a thickness of the bone member must be made larger than the diameter of the probe. That is, there is a problem that the bone member must be selected corresponding to the diameter of the probe.

Likewise, if an integrated piping plate is to be manufactured by the FSW, as a distance between adjacent fluid passage grooves cannot be made smaller than the diameter of the probe, there is a restriction that the degree of the integration is decided by the diameter of the probe.

Also, there is a restriction of the welding speed such that the welding speed is decided by the time until the frictional heat is generated by the FSW tool.

Also, there is a conventional FSW method in which a heating source other than generating the frictional heat by the FSW is additionally provided at and around the weld portion to thereby enhance the welding speed. For example, as shown by perspective views of FIGS. 10, 11 and 12, a rotating probe 53 is inserted into a weld portion 54 between weld object members 50, 51, both made of aluminum, and a contact portion of the weld object members 50, 51 making contact with the probe 53 is softened by the frictional heat and stirred by the probe 53. In this state, a FSW tool 52 together with the probe 53 is moved along the weld portion 54 so that the weld object members 50, 51 are welded together, wherein a front portion of the weld portion 54 in a moving direction X of the probe 53 is heated by an outside heating source (laser beam 55 in FIG. 10, gas flame 56 in FIG. 11 and a heating roller 57 in FIG. 12) so that temperature there becomes 100 to 300° C. This is proposed in Patent Document 1 mentioned below.

Also, as shown by a perspective view of FIG. 13, a heating device comprises a FSW tool having a probe 53 that moves on a weld portion 54 of weld object members 50, 51, induction heating sources 58, 59 arranged at front and rear positions of the probe 53 so as to move together with the probe 53, a power source 60 supplying the induction heating sources 58, 59 with electric power and a temperature setting means 61 setting a temperature of the weld portion 54 and a gap is provided between the induction heating sources 58, 59 and the weld object members 50, 51. At the time of welding, the induction heating sources 58, 59 are heated by the power source 60 to a set temperature set by the temperature setting means 61, so that front and rear portions of the weld portion 54 in the moving direction X of the probe 53 are heated by the induction heating sources 58, 59. This is proposed in Patent Document 2 mentioned next.

(Patent Document 1) Japanese published patent 3081808 (FIGS. 1, 2 and 3) (Patent Document 2) Japanese laid-open patent application 2003-94175 (FIG. 1)

Nevertheless, the methods of the above-mentioned Patent Documents 1 and 2 are no more than for the purpose that the pre-heating is done for shortening the treatment time of the FSW method and the post heating is done for enhancing the quality after the treatment and there are problems such that places to be heated are distant from the place where the FSW is being carried out so that an effective control of the degree of heating and softening of the place where the FSW is being carried out is difficult, a large power (electric power) is needed for driving the FSW tool and a large FSW tool that is more than needed must be used.

SUMMARY OF THE INVENTION

With a view to solving the problems in the prior art, it is an object of the present invention to provide a FSW method and apparatus by which a power needed for performing the FSW can be reduced and a FSW tool having a compact size can be used.

In order to achieve the above-mentioned object, the present invention provides each of inventions mentioned in the scope of Claims for patent employing the following means of (1) to (13) as the FSW method and apparatus:

(1) As a first means, a FSW (friction stir welding) method comprising the steps of lapping metal members one on another and inserting a rotating probe of a FSW tool into a contact portion of the metal members making contact with the probe so that the contact portion is softened by a frictional heat and stirred by the probe and the metal members are welded together, characterized in that a portion of the metal members surrounding the probe is heated by a heating means.

(2) As a second means, a FSW method as mentioned in the first means, characterized in that the probe and a rotator of the FSW tool are made of a non-conductive material and the heating means effects an electromagnetic induction heating.

(3) As a third means, a FSW method as mentioned in the second means, characterized in that the heating means is provided concentrically with the FSW tool and an electromagnetic wave shielding means is arranged above the heating means.

(4) As a fourth means, a FSW method as mentioned in any one of the first to third means, characterized in that a temperature measuring means measuring a heating temperature of the metal members is provided in the vicinity of the FSW tool and an output of the heating means is controlled based on a measured value of the heating temperature.

(5) As a fifth means, a FSW method as mentioned in any one of the first to third means, characterized in that a rotational state of the probe is measured and an output of the heating means is controlled based on the rotational state.

(6) As a sixth means, a FSW method as mentioned in any one of the first to fifth means, characterized in that a distance between the heating means and a surface of the metal members is adjustable.

(7) As a seventh means, a FSW method as mentioned in the first means, characterized in that the heating means is provided concentrically with the FSW tool and the heating means is pressed against the metal members by a pressing means.

(8) As an eighth means, a FSW method as mentioned in the first means, characterized in that the heating means is provided at a front position of the probe in a moving direction of the probe and an inspection of a portion welded by the FSW at a rear position of the probe in the moving direction of the probe is carried out.

(9) As a ninth means, a FSW method as mentioned in the eighth means, characterized in that a plurality of pressing means are arranged around the FSW tool.

(10) As a tenth means, a FSW method as mentioned in the eighth or ninth means, characterized in that the heating means, while it is moved in the moving direction of the probe, is revolved via a revolving stand.

(11) As an eleventh means, a FSW (friction stir welding) apparatus effecting a FSW of metal members lapped one on another, characterized in comprising a FSW tool having a probe and a rotator, both made of a non-conductive material, an electromagnetic induction heating means provided in the vicinity of, and concentrically with, the FSW tool and an electromagnetic wave shielding means provided above the electromagnetic induction heating means.

(12) As a twelfth means, a FSW apparatus as mentioned in the eleventh means, characterized in further comprising a temperature measuring means provided in the vicinity of the FSW tool, a temperature setting means setting a predetermined temperature, a comparing means computing a temperature difference between a measured temperature measured by the temperature measuring means and a set temperature set by the temperature setting means and a power supply means controlling a supply current or a supply power to be supplied into the electromagnetic induction heating means based on a computed result computed by the comparing means.

(13) As a thirteenth means, a FSW apparatus as mentioned in the eleventh means, characterized in further comprising a probe rotational state measuring means measuring a rotational state of the probe and a power supply means enlarging a supply current or a supply power to be supplied into the electromagnetic induction heating means corresponding to a size of a measured value measured by the probe rotational state measuring means.

According to each of the inventions as claimed in Claims as appended herein, each of the above-mentioned means (1) to (13) is provided and effects of the invention are obtained as follows:

(1) As the invention of Claim 1 employs the above-mentioned first means, the portion of the metal members surrounding the probe is heated and the contact portion of the metal members with the probe that is softened by the frictional heat of the rotating probe of the FSW tool and stirred by the probe can be more appropriately and easily softened.

(2) As the invention of Claim 2 employs the above-mentioned second means, in addition to the effect of the invention of Claim 1, by providing the heating means effecting the electromagnetic induction heating, the weld portion to be welded by the FSW is heated by the electromagnetic induction heating. Also, by employing the probe and rotator of the FSW tool made of a non-conductive material, the probe and rotator that rotate at a high speed are in no case heated by the electromagnetic induction and a strength deterioration caused in, or a thermal influence acting on, an upper drive portion of the FSW tool or other supporting portions can be avoided.

(3) As the invention of Claim 3 employs the above-mentioned third means, in addition to the effect of the invention of Claim 2, by providing the heating means concentrically with the FSW tool, the weld portion frictionally stirred by the probe can be concentrically heated. Also, even in the case where the welding direction (moving direction of the probe) is bent windingly or like a U-shape, the heating at the weld portion becomes uniform and an efficient welding can be carried out.

Further, by the electromagnetic wave shielding means, no bad influence, such as heat generation or strain by heat, is given on the surrounding metal-made parts and components.

(4) As the invention of Claim 4 employs the above-mentioned fourth means, in addition to the effect of the invention of any one of Claims 1 to 3, the heating temperature is measured by the temperature measuring means and by controlling the output of the heating means based on the measured value of the heating temperature, an efficient FSW can be carried out.

(5) As the invention of Claim 5 employs the above-mentioned fifth means, in addition to the effect of the invention of any one of Claims 1 to 3, the rotational state of the probe is measured and by controlling the output of the heating means so as to be increased when the revolution of the probe is decreased or when the current rotating the probe is increased, an efficient FSW can be carried out.

(6) As the invention of Claim 6 employs the above-mentioned sixth means, in addition to the effect of the invention of any one of Claims 1 to 5, the heat generation can be adjusted by making the distance between the heating means and the surface of the metal members adjustable.

(7) As the invention of Claim 7 employs the above-mentioned seventh means, in addition to the effect of the invention of Claim 1, the heating means provided concentrically with the FSW tool is pressed against the metal members by the pressing means and the heat generation due to the frictional heat by the probe can be made less so that the force acting on the FSW tool can be reduced. Thereby, the life of the FSW tool can be elongated and the apparatus can be made smaller.

(8) As the invention of Claim 8 employs the above-mentioned eighth means, in addition to the effect of the invention of Claim 1, the heating means is provided at the front position of the probe in the moving direction of the probe and the portion welded by the FSW is inspected at the rear position of the probe in the moving direction of the probe. Thus, no excessively large load is needed to act on the probe and shoulder portion so that the size of the FSW tool can be made smaller. Also, the work speed can be enhanced so as to contribute to reducing the man-hour.

Further, by carrying out the inspection at the same time with the welding work, a work failure can be instantly corrected so that the fraction defective can be reduced and the yield of the products can be remarkably enhanced.

(9) As the invention of Claim 9 employs the above-mentioned ninth means, in addition to the effect of the invention of Claim 8, the plurality of pressing means are arranged around the FSW tool. Thereby, the upper and lower plates are caused to make close contact with each other by an appropriate pressing force so that a separation of the upper and lower plates from each other, their vibration, etc. caused by stirring by the probe can be avoided and the welding work by the FSW can be ensured.

(10) As the invention of Claim 10 employs the above-mentioned tenth means, in addition to the effect of the invention of Claim 8 or 9, the heating means, while moving in the moving direction of the probe, is revolved via the revolving stand. Thereby, even if the welding direction (moving direction of the probe) is bent windingly or in a U-shape, heating of the weld portion becomes uniform and an efficient welding can be carried out.

(11) As the invention of Claim 11 employs the above-mentioned eleventh means, the probe and rotator of the FSW tool are made of a non-conductive material and the probe and rotator rotating at a high speed are in no case heated by the electromagnetic induction. Thus, a strength deterioration of, or a thermal influence acting on, the upper drive portion of the FSW tool or other supporting portions are avoided. Also, by providing the electromagnetic heating means concentrically with the FSW tool, the portion applied with the FSW by the probe can be concentrically heated. Further, even if the welding direction (moving direction of the probe) is bent windingly or in a U-shape, heating of the weld portion becomes uniform and an efficient welding can be carried out. Also, by the electromagnetic wave shielding means, no bad influence of the heat generation and strain by heat acts on the surrounding metal-made parts and components.

(12) As the invention of Claim 12 employs the above-mentioned twelfth means, in addition to the effect of the invention of Claim 11, the heating temperature is measured by the temperature measuring means and the output of the electromagnetic induction heating means is controlled based on the measured value of the heating temperature. Thereby, an efficient FSW can be carried out.

(13) As the invention of Claim 13 employs the above-mentioned thirteenth means, in addition to the effect of the invention of Claim 11, the rotational state of the probe is measured and by controlling the output of the heating means so as to be increased when the revolution of the probe is decreased or when the current rotating the probe is increased, an efficient FSW can be carried out.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross sectional front view showing a state that a FSW tool of a first embodiment according to the present invention performs a welding work.

FIG. 2 is a cross sectional view taken on line A-A of FIG. 1.

FIG. 3 is a cross sectional view taken on line B-B of FIG. 1.

FIG. 4 is a control diagram of the FSW tool of FIG. 1.

FIG. 5 is a cross sectional front view showing a state that a FSW tool of a second embodiment according to the present invention performs a welding work.

FIG. 6 is a cross sectional view taken on line C-C of FIG. 5.

FIG. 7 is a cross sectional front view showing a state that a FSW tool of a third embodiment according to the present invention performs a welding work.

FIG. 8 is a cross sectional view taken on line D-D of FIG. 7.

FIG. 9 is a perspective view showing one example of an integrated piping plate that is appropriate to be welded by the FSW tools of the embodiments of the present invention.

FIG. 10 is a perspective view showing a prior art heating method by means of a laser.

FIG. 11 is a perspective view showing a prior art heating method by means of a gas burner.

FIG. 12 is a perspective view showing a prior art heating method by means of a heating roller.

FIG. 13 is a perspective view showing a prior art heating method by means of an induction heating.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Herebelow, embodiments according to the present invention will be described with reference to appended drawings.

FIG. 1 is a cross sectional front view showing a state that a FSW tool of a first embodiment of the present invention performs a welding work, FIG. 2 is a cross sectional view taken on line A-A of FIG. 1 and FIG. 3 is a cross sectional view taken on line B-B of FIG. 1. FIG. 4 is a control diagram of the FSW tool of FIG. 1.

FIG. 5 is a cross sectional front view showing a state that a FSW tool of a second embodiment of the present invention performs a welding work and FIG. 6 is a cross sectional view taken on line C-C of FIG. 5.

FIG. 7 is a cross sectional front view showing a state that a FSW tool of a third embodiment of the present invention performs a welding work and FIG. 8 is a cross sectional view taken on line D-D of FIG. 7.

FIG. 9 is a perspective view showing one example of an integrated piping plate that is appropriate to be welded by the FSW tools of the embodiments of the present invention.

First, an example of a structure of an integrated piping plate that is appropriate to be welded by the FSW will be described with reference to FIG. 9.

As shown there, the integrated piping is constructed by an upper plate 1 and a lower plate 2, and a plurality of connectors 9 or the like of a device, such as a device of a fuel cell power generating system or the like, are arranged on a surface of the upper plate 1.

Each of the connectors 9 is fixed to an integrally formed plate-like unit of the upper and lower plates 1, 2, welded together by the FSW, via a plurality of stud bolts 7 and nuts 8 or the like.

A plurality of fluid passages connecting between and among the plurality of connectors 9 provided on the upper plate 1 are formed in a weld surface 4 portion of the lower plate 2 that is welded to a lower surface of the upper plate 1. That is, the lower plate 2 has its upper surface portion formed with a plurality of fluid passage grooves 3 (3 a, 3 b) and each of the fluid passages is formed by the upper plate 1 being lapped on the lower plate 2 and by peripheral portions of each of the fluid passage grooves 3 being welded liquid-tight by the FSW.

The fluid passages are provided in a form that they are windingly bent or a plurality of them are arrayed or in other forms. Each of the fluid passages is constructed so as to communicate with one or more of the connectors 9 via respective communication holes 6 provided in the upper plate 1. That is, the fluid passages and the communication holes 6 function as pipings through which a necessary fluid (liquid or gas) flows into, or flows out of, various devices connected to the integrated piping plate.

Next, a FSW tool of the first embodiment and a FSW method thereof according to the present invention will be described with reference to FIGS. 1, 2, 3 and 4.

As shown in FIGS. 1, 2 and 3, a rotator 11 a of a FSW tool 10 a to be used for the FSW is fixed to a rotating shaft of a rotator drive motor 15 (FIG. 4) provided on a moving and supporting stand (not shown) to be rotated at a high speed by the rotator drive motor 15. The rotator 11 a is formed having a truncated-conical shape and is provided having its smaller diameter side flat surface arranged downwardly. A flat shoulder portion 13 is formed on this smaller diameter side flat surface. A probe 12 a is provided projecting from a central portion of the shoulder portion 13 to be rotated together with the rotator 11 a. Also, a ring-like groove 14 is formed in a surface portion of the shoulder portion 13.

It is to be noted that a material of the rotator 11 a and probe 12 a is selected from non-conductive materials (ceramics or other non-metals) as it is preferable that no heat is generated by an electromagnetic induction action. By so constructing the rotator 11 a and probe 12 a by a non-conductive material, the rotator 11 a and probe 12 a are in no case heated by a heating coil 21, to be described later, so that a strength deterioration of the rotator 11 a and probe 12 a is avoided and a thermal influence acting on the rotator drive motor 15, provided above the FSW tool 10 a, and the moving and supporting stand can be eliminated.

A heating coil 21 having a doughnut-like shape as a heating means 20 a for effecting an induction heating is arranged around, and concentrically with, the rotator 11 a with an appropriate gap maintained between the heating coil 21 and the rotator 11 a. This heating coil 21 is fixed to the moving and supporting stand and is supplied with a high frequency electric power from a heating coil control unit 40 (FIG. 4) via a wiring arranged on the moving and supporting stand.

As the induction heating device including the heating coil 21, etc. can be employed from those generally obtainable in the market, a detailed description thereof will be omitted but it is constructed, as shown in FIG. 4, by the heating coil 21, a high frequency electric power generator 42, a matching section output transformer 41, a cooling unit (not shown) cooling the heating coil 21, etc.

The heating coil 21 is constructed by a coil having multiple turns and when the heating coil 21 is supplied with a high frequency current by the heating coil control unit 40, an eddy current is generated in adjacent portions of the upper plate 1 and lower plate 2 by the electromagnetic induction action, so that the adjacent portions of the upper plate 1 and lower plate 2 are rapidly heated by heat generated by eddy current loss and hysteresis loss. A center of this heating is a central portion of the heating coil 21, that is, a portion that is being stirred by the probe 12 a.

It is to be noted that a lower end of the heating coil 21 is positioned slightly above the level of the shoulder portion 13 of the rotator 11 a.

Generally, in the induction heating, the eddy current flows more in the portion near a workpiece surface. Thus, the heat is generated more in the surface portion so that the temperature there becomes higher and then in the portion approaching a further inside, the heat is exponentially less generated. Hence, in the FSW carried out in the present embodiment, the induction heating is appropriate for heating the weld portion in which the probe 12 a is inserted.

Also, as shown in FIG. 2, a temperature sensor 23 (a thermocouple, for example) is arranged in the vicinity of the shoulder portion 13. This temperature sensor 23 also is fitted to the moving and supporting stand.

It is to be noted that the illustration of FIG. 2 shows one piece only of the temperature sensor 23 arranged in front of the shoulder portion 13 in the moving direction X of the rotator 11 a. Nevertheless, as the FSW tool 10 a moves not only in the moving direction X but also in the reverse direction thereof as well as in the crossing direction thereof, the temperature sensor 23 may be provided with four pieces thereof, for example, arranged being equally spaced between each of them in the vicinity of the shoulder portion 13.

Moreover, a ring-shaped electromagnetic wave shielding plate 22 is arranged above the heating coil 21 with an appropriate gap maintained between this electromagnetic wave shielding plate 22 and the rotator 11 a. This electromagnetic wave shielding plate 22 also is fitted to the moving and supporting stand. It is to be noted that the heating coil 21 and electromagnetic wave shielding plate 22 may be fitted to the moving and supporting stand separately from each other or may be first integrated together to then be fitted to the moving and supporting stand.

It is preferable that a radial directional width of the ring-shaped electromagnetic wave shielding plate 22 is made larger than a radial directional width of the heating coil 21. Also, this electromagnetic wave shielding plate 22 may be shaped so as to cover an upper half portion of the heating coil 21.

By so arranging the electromagnetic wave shielding plate 22 of an appropriate shape around the heating coil 21, no bad influence, such as heat generation or strain by heat, is given on the surrounding metal-made parts and components.

Next, a control of the heating coil 21 as the heating means 20 a will be described with reference to FIG. 4.

The rotator drive motor 15 is supplied with a power (or current) by a FSW tool control unit 47. This FSW tool control unit 47 comprises a power meter (or ammeter) detecting a supply power (or supply current) supplied into the rotator drive motor 15.

It is to be noted that, as shown in FIG. 4, the rotator drive motor 15 driving the rotator 11 a may comprise a revolution detector 16 detecting a revolution of the motor 15.

Respective signals from the power meter (or ammeter) of the FSW tool control unit 47 or the revolution detector 16 and the temperature sensor 23 arranged around the shoulder portion 13 are inputted into the heating coil control unit 40.

The heating coil control unit 40 comprises a setting unit 43. Before the FSW work is started, a preliminary welding is carried out with respect to the upper plate 1 and lower plate 2 to be applied with the FSW so that appropriate values of the supply power (or supply current) into the heating coil 21 and the frequency thereof, the supply power (or supply current) into the rotator drive motor 15 or the revolution thereof, the moving speed of the FSW tool 10 a and the temperature around the shoulder portion 13 are previously obtained. These values obtained by the preliminary welding are inputted into the setting unit 43 to be stored therein as respective predetermined set values. Also, the setting unit 43 is so constructed that an operation mode, such as a speed-constant control, a weld portion temperature-constant control or the like, can be set therein.

A signal of the measured temperature from the temperature sensor 23 is inputted into a comparing unit 45 a provided in the heating coil control unit 40. As the temperature sensor 23 is usually provided with plural pieces thereof (four pieces, for example), an average value of respective detected values from the plural temperature sensors 23 is computed or a minimum temperature thereof is selected to be inputted into the comparing unit 45 a. Also, the comparing unit 45 a is inputted with a predetermined temperature set value obtained by the preliminary welding and stored in the setting unit 43.

The comparing unit 45 a compares the measured temperature signal with the predetermined temperature set value so that a temperature deviation value is computed to be inputted into a heating coil output computing unit 44.

Also, a signal of the supply power (or supply current) into the rotator drive motor 15 detected by the FSW tool control unit 47 is inputted into a comparing unit 45 c provided in the heating coil control unit 40. Also, the comparing unit 45 c is inputted with a predetermined supply power (or supply current) set value obtained by the preliminary welding and stored in the setting unit 43.

The comparing unit 45 c compares the measured supply power (or supply current) signal from the FSW tool control unit 47 with the predetermined supply power (or supply current) set value so that a supply power (or supply current) deviation value is computed to be inputted into the heating coil output computing unit 44.

Otherwise, a signal of the revolution of the rotator drive motor 15 detected by the revolution detector 16 is inputted into a comparing unit 45 b provided in the heating coil control unit 40. Also, the comparing unit 45 b is inputted with a predetermined revolution set value obtained by the preliminary welding and stored in the setting unit 43.

The comparing unit 45 b compares the measured revolution signal with the predetermined revolution set value so that a revolution deviation value is computed to be inputted into the heating coil output computing unit 44.

The heating coil output computing unit 44 computes a current value to be inputted into the heating coil 21 based on these inputted values of the temperature deviation value and supply power (or supply current) deviation value or revolution deviation value.

For example, if a rotational resistance of the rotator 11 a has been increased by a difference of the material, etc. between the upper plate 1 and the lower plate 2, then, by the increase of the resistance, the supply power (or supply current) into the rotator drive motor 15 is increased or the revolution of the rotator 11 a is decreased.

If the operation mode is of a speed-constant control, in order to maintain the moving speed of the FSW tool 10 a, it is necessary, for example, to increase the supply current into the heating coil 21 so that the upper plate 1 and lower plate 2 are more heated and softened.

In this case, the heating coil output computing unit 44 computes a current target value to be inputted into the heating coil 21 based on the supply power (or supply current) deviation value from the comparing unit 45 c or the revolution deviation value from the comparing unit 45 b.

It is to be noted that the temperature deviation value is monitored so as not to exceed a maximum temperature to thereby avoid a deterioration, etc. of the upper plate 1 and lower plate 2.

The computed current target value is inputted into the high frequency power generator 42. The high frequency power generator 42 controls a firing angle, etc. of a power converter, such as a power transistor, thyristor or the like, based on the current target value. Thereby, the supply power (or supply current) is regulated to be supplied into the heating coil 21 of the heating means 20 a via the matching section output transformer 41.

Next, if the operation mode is of a weld portion temperature-constant control, the heating coil output computing unit 44 computes a current target value to be inputted into the heating coil 21 based on the temperature deviation value so that the temperature deviation value from the comparing unit 45 a becomes zero.

The computed current target value is inputted into the high frequency power generator 42 so that the supply power (or supply current) is regulated to be supplied into the heating coil 21 via the matching section output transformer 41.

It is to be noted that in case where the supply power (or supply current) deviation value from the comparing unit 45 c or the revolution deviation value from the comparing unit 45 b increases or the supply power (or supply current) increases or the revolution decreases, a moving and supporting stand control unit 48 controlling movement of the moving and supporting stand is inputted with the supply power (or supply current) deviation value or the revolution deviation value to thereby control the moving speed to be reduced so that the supply power (or supply current) deviation value or the revolution deviation value becomes zero.

Next, by using the apparatus of the first embodiment of the present invention constructed by the FSW tool 10 a, heating means 20 a, electromagnetic wave shielding plate 22, moving and supporting stand and control unit, as mentioned above, a method for working the integrated piping plate comprising the upper and lower plates 1, 2, as shown in FIG. 9, will be described.

It is to be noted that in the present embodiment, as the heating is done by the electromagnetic induction heating, the upper and lower plates 1, 2 are made of a conductive material, such as aluminum, copper, carbon steel or the like, or other magnetic materials.

As shown in FIGS. 1, 2 and 3, the upper plate 1 is lapped on the lower plate 2 in which the plurality of fluid passage grooves 3 are formed in advance. The FSW tool 10 a comprising the probe 12 a, etc. is moved toward the moving direction X and thereby the weld portion 5 welded by the FSW is formed, wherein the FSW tool 10 a is moved along entire outer peripheries of the winding fluid passage grooves 3. Thus, the weld surface 4 is formed between the upper and lower plates 1, 2 so that the upper and lower plates 1, 2 are welded to be fixed together in a liquid-tight state.

According to the above-described FSW method and apparatus, the upper plate 1 and lower plate 2 are applied with the induction heating by the heating coil 21. Hence, the heating is done rapidly and noncontact-wise up to a needed internal depth in the upper and lower plates 1, 2 and a local plastic fluid area can be easily and efficiently formed.

Also, as the non-contact heating means 20 a is used, no complicated mechanism to follow variations of surface shapes of the workpiece is needed and the apparatus can be made less expensive and in a simplified manner.

Moreover, if the integrated piping plate is to be worked, as the upper plate 1 and lower plate 2 make no contact with each other in the portion of the fluid passage grooves 3, the heat can be concentrated on the weld portion to be welded where the upper plate 1 and lower plate 2 make contact with each other. Hence, heating of a needed position can be done more efficiently.

Also, as no large pressing force and rotational drive force act on the FSW tool 10 a, a diameter d2 of the shoulder portion 13 and a diameter d1 of the probe 12 a can be made smaller and the entire apparatus can be made smaller. Thereby, a manufacture of a compact product, that is, for example, an integrated piping plate having a high integration degree in which adjacent fluid passage grooves 3 are more approached each other, becomes possible.

Further, as a heat source needed for the FSW less relies on the frictional heat caused by the rotational drive of the FSW tool 10 a, the welding speed can be elevated to thereby contribute to shortening the work time.

Moreover, as the heating means 20 a is arranged concentrically with the FSW tool 10 a, even if the welding direction (moving direction of the probe) is bent like a hairpin or U letter, as shown in the example of working the integrated piping plate, heating of the weld portion becomes uniform and an efficient welding becomes possible.

While the above description is made such that the supply power (or supply current) into the heating coil 21 is controlled based on the temperature detected by the temperature sensor 23 and the revolution of the rotator drive motor, the supply power into the heating coil 21 may instead be maintained constant.

In this case, the construction may also be made such that a distance between the heating coil 21 (and the electromagnetic wave shielding plate 22) and the workpiece is adjustable. That is, for example, the heating coil 21 (and the electromagnetic wave shielding plate 22) is connected to the moving and supporting stand via a telescopic joint of which length is controllable so that the distance from the workpiece can be adjusted.

It is to be noted that while the description of the above embodiment and the function and effect thereof is exemplified by the case of working the integrated piping plate, the present invention is by no means limited thereto but may also be applied to welding of other various products.

Next, a FSW tool of a second embodiment of the present invention and a FSW method thereof will be described with reference to FIGS. 5 and 6.

As shown there, a rotator 11 b of a FSW tool 10 b used for the FSW is fixed to a rotating shaft of a rotator drive motor 15 (FIG. 4) provided on a moving and supporting stand (not shown) to be rotated at a high speed by the rotator drive motor 15. A lower portion of the rotator 11 b is formed with a cylindrical shape having a lower flat surface portion. A flat shoulder portion 13 is formed on this lower flat surface portion.

A probe 12 b is provided projecting from a central portion of the shoulder portion 13 to be rotated together with the rotator 11 b. A material of the rotator 11 b and probe 12 b is selected from ceramics, hard metals or the like having a high heat resistance and high strength.

A doughnut-like heater 25 constituting a heating means 20 b for pre-heating the weld portion 5 is arranged around, and concentrically with, the rotator 11 b with an appropriate gap maintained between the heater 25 and the rotator 11 b. A heating element 26 generating heat by an electric resistance or the like is provided in the heater 25.

A material of the heater 25 is selected from metals or the like having a high heat resistance and high heat conductivity so that heat generated by the heating element 26 provided in the heater 25 is efficiently transmitted to the upper and lower plates 1, 2.

The heater 25 has its upper surface fixed with a plurality of supporting members 27 and these supporting members 27 are fitted to the moving and supporting stand so as to slidably move up and down relative to the moving and supporting stand.

A compression spring 28 is interposed between the heater 25 and the moving and supporting stand and the construction is made such that the heater 25 moves together with the FSW tool 10 b, while the heater 25 makes contact with the upper plate 1 with an appropriate urging force maintained against the upper plate 1 by the compression spring 28.

Next, by using the apparatus of the second embodiment of the present invention constructed by the FSW tool 10 b, heating means 20 b, etc., as mentioned above, a method for working the integrated piping plate comprising the upper and lower plates 1, 2, as shown in FIG. 9, will be described.

As shown in FIGS. 5 and 6, the upper plate 1 is lapped on the lower plate 2 in which the plurality of fluid passage grooves 3 are formed in advance so that the FSW is carried out along peripheries of the fluid passage grooves 3, as in the first embodiment. The FSW tool 10 b that comprises the probe 12 b integrally constructed with the shoulder portion 13 and projecting from the central portion of the shoulder portion 13 is moved in the moving direction X while the FSW tool 10 b is driven to rotate in the normal and reverse directions by a drive unit (not shown).

According to the FSW carried out by the FSW tool 10 b and heating means 20 b of the pre-heating type of the above-described second embodiment, pre-heating is done by the heating means 20 b. Thereby, heat generation by the frictional heat of the probe 12 b can be made less and a force acting on the FSW tool 10 b also can be made less. Hence, the life of the FSW tool 10 b can be elongated and the apparatus can be made smaller. Also, the width of the fluid passage grooves 3 can be made narrower and the integration degree can be enhanced. Moreover, by the upper plate 1 and lower plate 2 being heated from outside by the pre-heating, the moving speed of the FSW tool 10 b, that is, the welding speed, can be increased and the efficiency of the work can be enhanced.

Next, a FSW tool of a third embodiment and a FSW method thereof will be described with reference to FIGS. 7 and 8.

As shown there, the upper plate 1, lower plate 2, fluid passage grooves 3 and FSW tool 10 b are the same as those of the second embodiment and description thereof will be omitted.

In FIGS. 7 and 8, a plurality of rollers 34 are arranged around, and at an appropriate distance away from, the FSW tool 10 b. Each of the rollers 34 is rotatably fitted to a pin 33 that has its both ends fixed to a holder 32.

Also, a revolving stand 38 is revolvably fitted to a moving and supporting stand (not shown). A plurality of struts 31 are fitted to a lower surface of the revolving stand 38 so as to slidably move up and down via cylinders or compression springs. The holder 32 is fixed to a lower (distal) end of each of the struts 31. Thus, a pressing means 29 is constructed by the rollers 34, holders 32, struts 31 and revolving stand 38. The rollers 34 constantly press down the upper plate 1 with a predetermined pressing force so that the upper plate 1 makes close contact with the lower plate 2.

Further, a heating means 20 c for heating the weld portion of the upper and lower plates 1, 2 is arranged at a close front position of the FSW tool 10 b in the moving direction X. This heating means 20 c also is fitted to the revolving stand 38 via support legs 36.

The heating means 20 c makes no contact with the upper plate 1 nor with the shoulder portion 13 and is appropriately selected, for example, from an induction heating device or the like. Nevertheless, it may also be selected from a heater or the like that makes contact with the upper plate 1 with an appropriate pressing force.

Also, an inspecting means 35 for inspecting a work quality of the weld portion 5 welded by the FSW is arranged at a rear position of the FSW tool 10 b. This inspecting means 35 also is fitted to the revolving stand 38.

The inspecting means 35 may be either of a contact type or a non-contact type and is selected from devices constructed such that signals of an image of a weld portion 5 surface taken by a CCD camera arranged noncontact-wise are inputted into a control section (not shown) or such that signals of an internal welded state taken by an ultrasonic or X-ray inspecting device provided making contact with the weld portion 5 are inputted into a control section (not shown).

The control section analyzes these signals and judges whether the welded state of the weld portion 5 is sufficient or not with respect to the heating state and the revolution and moving speed of the FSW tool 10 b, so that the operation conditions of the heating temperature of the weld portion 5 and the pressure, revolution and moving speed of the FSW tool 10 b, etc. can be controlled to an optimal state.

By the construction of the heating means 20 c, inspecting means 35 and pressing means 29 being fitted to the revolving stand 38, when the FSW tool 10 b makes linear or winding movements along the weld portion 5, these devices can move together with the FSW tool 10 b.

According to the FSW carried out by the FSW tool 10 b, heating means 20 c and pressing means 29 of the above-described third embodiment, no large load acts on the probe 12 and shoulder portion 13 and their sizes can be made smaller. If an integrated piping plate is to be manufactured, the integration degree can be enhanced and, at the same time, the work speed can be enhanced, thereby contributing to reducing the man-hour.

Also, by providing the inspecting means, the welding quality can be inspected at the same time. Thereby, a work failure can be instantly corrected on-line so that the fraction defective can be reduced and the yield of the products can be remarkably enhanced.

Moreover, by the plurality of pressing means 29, the portion near the probe 12 of the upper plate 1 is pressed down with an appropriate pressing force. Thereby, the upper plate 1 makes close contact with the lower plate 2 and a separation of the upper plate 1 from the lower plate 2 or their vibration caused by stirring by the probe 12 can be prevented so that the welding is ensured.

In the above, while the present invention has been described with respect to the first to the third embodiments, the present invention is by no means limited thereto but, needless to mention, may be added with various modifications and variations in the concrete structure within the scope of claims of the invention as appended hereto. 

1. A FSW (friction stir welding) method comprising the steps of lapping metal members one on another and inserting a rotating probe of a FSW tool into a contact portion of said metal members making contact with said probe so that said contact portion is softened by a frictional heat and stirred by said probe and said metal members are welded together, wherein a portion of said metal members surrounding said probe is heated by a heating means.
 2. A FSW method as claimed in claim 1, wherein said probe and a rotator of said FSW tool are made of a non-conductive material and said heating means effects an electromagnetic induction heating.
 3. A FSW method as claimed in claim 2, wherein said heating means is provided concentrically with said FSW tool and an electromagnetic wave shielding means is arranged above said heating means.
 4. A FSW method as claimed in claim 1, wherein a temperature measuring means measuring a heating temperature of said metal members is provided in the vicinity of said FSW tool and an output of said heating means is controlled based on a measured value of said heating temperature.
 5. A FSW method as claimed in claim 1, wherein a rotational state of said probe is measured and an output of said heating means is controlled based on said rotational state.
 6. A FSW method as claimed in claim 1, wherein a distance between said heating means and a surface of said metal members is adjustable.
 7. A FSW method as claimed in claim 1, wherein said heating means is provided concentrically with said FSW tool and said heating means is pressed against said metal members by a pressing means.
 8. A FSW method as claimed in claim 1, wherein said heating means is provided at a front position of said probe in a moving direction of said probe and an inspection of a portion welded by the FSW at a rear position of said probe in the moving direction of said probe is carried out.
 9. A FSW method as claimed in claim 8, wherein a plurality of pressing means are arranged around said FSW tool.
 10. A FSW method as claimed in claim 8, wherein said heating means, while it is moved in the moving direction of said probe, is revolved via a revolving stand.
 11. A FSW (friction stir welding) apparatus effecting a FSW of metal members lapped one on another, comprising a FSW tool having a probe and a rotator, both made of a non-conductive material, an electromagnetic induction heating means provided in the vicinity of, and concentrically with, said FSW tool and an electromagnetic wave shielding means provided above said electromagnetic induction heating means.
 12. A FSW apparatus as claimed in claim 11, further comprising a temperature measuring means provided in the vicinity of said FSW tool, a temperature setting means setting a predetermined temperature, a comparing means computing a temperature difference between a measured temperature measured by said temperature measuring means and a set temperature set by said temperature setting means and a power supply means controlling a supply current or a supply power to be supplied into said electromagnetic induction heating means based on a computed result computed by said comparing means.
 13. A FSW apparatus as claimed in claim 11, further comprising a probe rotational state measuring means measuring a rotational state of said probe and a power supply means enlarging a supply current or a supply power to be supplied into said electromagnetic induction heating means corresponding to a size of a measured value measured by said probe rotational state measuring means.
 14. A FSW method as claimed in claim 2, wherein a temperature measuring means measuring a heating temperature of said metal members is provided in the vicinity of said FSW tool and an output of said heating means is controlled based on a measured value of said heating temperature.
 15. A FSW method as claimed in claim 3, wherein a temperature measuring means measuring a heating temperature of said metal members is provided in the vicinity of said FSW tool and an output of said heating means is controlled based on a measured value of said heating temperature.
 16. A FSW method as claimed in claim 2, wherein a rotational state of said probe is measured and an output of said heating means is controlled based on said rotational state.
 17. A FSW method as claimed in claim 3, wherein a rotational state of said probe is measured and an output of said heating means is controlled based on said rotational state.
 18. A FSW method as claimed in claim 2, wherein a distance between said heating means and a surface of said metal members is adjustable.
 19. A FSW method as claimed in claim 3, wherein a distance between said heating means and a surface of said metal members is adjustable.
 20. A FSW method as claimed in claim 4, wherein a distance between said heating means and a surface of said metal members is adjustable. 